Substrate processing apparatus and substrate processing method

ABSTRACT

A substrate transfer system to reduce total processing time by transferring a substrate at a first delivery stage to a process block where processing can be carried out earliest. The substrate processing apparatus includes a first transfer device delivering a wafer with respect to a substrate carrier, and a second transfer device delivering a wafer between a plurality of process blocks and the first transfer device via a first delivery stage, to transfer the wafer with respect to the process blocks. The process block where there is no wafer or where processing of the last wafer within the relevant process block will be completed earliest is determined based on processing information of the wafers from the process blocks, and the wafer of the first delivery stage is transferred by the second transfer device to the relevant process block. This ensures smooth transfer of the wafer to the process block.

TECHNICAL FIELD

The present invention relates to a substrate processing apparatus and asubstrate processing method that perform prescribed substrateprocessing, such as coating of a resist solution and developing afterexposure to light, by applying a process solution on a surface of asubstrate, such as a semiconductor wafer or an LCD substrate (glasssubstrate for liquid crystal display).

BACKGROUND ART

In a manufacturing process of a semiconductor device, photolithographyis used, where a substrate such as a semiconductor wafer (hereinafter,referred to as a “wafer”) is coated with a resist solution, and theresist film is exposed to light using a photo mask and then developed tothereby form a desired resist pattern on the substrate. Such processingis generally carried out using a substrate processing apparatus having alight exposure device connected to a coating and developing device usedfor coating of the resist solution and developing.

In order to reduce the area occupied by the apparatus while ensuringhigh throughput, the substrate processing apparatus is configured suchthat different kinds of processing, such as coating, developing, andheating/cooling, are performed on a substrate using separate units, anda required number of such units for each processing are incorporated inthe apparatus. Transfer means for loading/unloading a substrate to/fromeach process unit is also provided.

An example of such a substrate processing apparatus will be describedwith reference to a configuration of Patent Document 1. In FIG. 16, 11represents a carrier stage 11 to/from which a carrier 10 containing 25wafers W, for example, is loaded/unloaded. For example, three processblocks 12A, 12B, 12C are connected to carrier stage 11, and a lightexposure device 12E is connected to the third process block 12C via aninterface block 12D. Process blocks 12A, 12B, 12C include transfer means13A, 13B, 13C, respectively, at the centers, and around the means, firstand second process blocks 12A, 12B have coating units 14A, 14B,respectively, for coating a wafer with a coating solution, third processblock 12C has a developing unit 15 for performing developing of thewafer after exposure to light, and all process blocks 12A-12C includeshelf units 16A-16G provided with heating unit, cooling unit, deliveryunit and others for performing prescribed heating or cooling processingon the wafer before or after the processing by coating unit 14 ordeveloping unit 15.

In this apparatus, the wafers in carrier 10 on carrier stage 11 aretaken out by a delivery arm 17, and transferred via a delivery unit ofshelf unit 16A to first process block 12A, and then sequentiallytransferred to unoccupied process units in first and second processblocks 12A, 12B in a prescribed order to be subjected to the coatingprocessing of the resist solution, and then transferred via processblock 12C and interface block 12D to light exposure device 12E, whereprescribed light exposure processing is performed. Thereafter, thewafers are again transferred to unoccupied process units in thirdprocess block 12C in a prescribed order to be subjected to thedeveloping processing. Before and after the coating and developingprocessing, heating and cooling processing is carried out in unoccupiedprocess units. Here, delivery of the wafers between first process block12A and second process block 12B, between second process block 12B andthird process block 12C, and between third process block 12C andinterface block 12D is carried out via delivery units of shelf units16C, 16E and 16G, respectively.

Patent Document 1: Japanese Patent Laying-Open No. 2000-124124 (see FIG.2)

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention

In the above-described substrate processing apparatus, a series ofprocessing are performed by first through third process blocks 12A-12Cas a whole, and the process units to be used and the transfer orderthrough the process units are predetermined in accordance with a processrecipe for wafers W. Further, in this apparatus, it is extremelydifficult to create a transfer program allowing the (n+1)-th wafer Wn+1having been introduced into first through third process blocks 12A-12Cfollowing the n-th wafer Wn to outpace the relevant wafer Wn, such thatthe succeeding wafer Wn+1 is subjected to processing prior to thepreceding wafer Wn. Such passing of wafer W cannot be effected.

Thus, in the current apparatus, assuming that wafer WA belonging to agroup A for which processing takes a long time is discharged fromcarrier C to a process block and then wafer WB belonging to a group Bfor which processing time is shorter than the processing time of group Ais discharged from carrier C to a process block, if wafers WB belongingto group B are successively discharged at the same timings as dischargeof wafers WA belonging to group A, wafer WB would catch up with waferWA, in which case wafer WB would be put on standby in the process blockuntil completion of processing of wafer WA. To prevent wafer WB frombeing put on standby in the process block, upon discharge of wafer WBfollowing wafer WA, it would be necessary to discharge wafer WB at atiming delayed from the discharge timing of wafer WA belonging to groupA. Putting wafer WB on standby in the process block until it can betransferred to a unit for the next step, or delaying the dischargetiming of wafer WB, would lead to an elongated total processing time,thereby degrading processing efficiency.

The present invention has been made in view of the foregoingcircumstances, and an object of the present invention is to provide asubstrate processing apparatus and a substrate processing method thatcan reduce the total processing time and improve the throughput bytransferring a substrate on a first delivery stage to a process blockwhere processing can be carried out earliest.

Means for Solving the Problems

To this end, the substrate processing apparatus of the present inventionincludes: a carrier block including a carrier placement portion to/fromwhich a substrate carrier storing a plurality of substrates isloaded/unloaded, and first transfer means for performing delivery of thesubstrate with respect to the substrate carrier placed on the carrierplacement portion; second transfer means provided adjacent to thecarrier block and for transferring the substrate along a linear transferpath extending in a lateral direction; a first delivery stage forperforming delivery of the substrate between the first transfer meansand the second transfer means; a plurality of process blocks eachincluding a plurality of process units for performing predeterminedprocessing on the substrate, third transfer means for transferring thesubstrate between the process units, and a second delivery stage forperforming delivery of the substrate between the second transfer meansand the third transfer means, the process blocks being provided withrespect to a main body of the apparatus to be arranged along thetransfer path, and performing a series of substrate processing on thesubstrates in units of the process blocks; a process block controlportion controlling operations of the third transfer means and therespective process units and outputting processing information of thesubstrates within the corresponding process block such thatpredetermined processing is performed on the substrates in each of theprocess blocks based on a predetermined recipe; and means fordetermining a process block where there is no substrate or where a finalstep for the last substrate within the relevant process block will befinished earliest based on the processing information of the substratesfrom the process block control portions before the substrate isdelivered from the first delivery stage to the second transfer means,and for controlling the second transfer means to transfer the substrateon the first delivery stage to the relevant process block.

Here, with respect to lots of substrates allocated in accordance withthe kinds of substrates, the means for controlling the second transfermeans may determine, before a first substrate in a certain lot isdelivered from the first delivery stage to the second transfer means, aprocess block where there is no substrate or where a final step for thelast substrate in the preceding lot of substrates now being performedwithin the relevant process block will be finished earliest, and controlthe second transfer means to transfer the first substrate in thesucceeding lot placed on the first delivery stage to the relevantprocess block.

In such a substrate processing apparatus, a substrate processing methodas described in the following is performed. The substrate processingmethod is provided with first transfer means for performing delivery ofa substrate with respect to a substrate carrier containing a pluralityof substrates, second transfer means for performing delivery of thesubstrate with respect to the first transfer means via a first deliverystage, and a plurality of process blocks each including a plurality ofprocess units for performing predetermined processing on the substrate,third transfer means for transferring the substrate between the processunits, and a second delivery stage for performing delivery of thesubstrate between the second transfer means and the third transfermeans, wherein a series of substrate processing are performed in theprocess blocks with respect to the substrates in the substrate carrierin units of the process blocks. The method includes the steps of: thefirst transfer means transferring the substrate within the substratecarrier to the first delivery stage; determining the process block wherethere is no substrate or where a final step for the last substratewithin the relevant process block will be finished earliest, based onprocessing information of the substrates in the respective processblocks, before the second transfer means receives the substrate of thefirst delivery stage; and subsequently, the second transfer meansreceiving the substrate placed on the first delivery stage andtransferring the relevant substrate to the determined process block.

In such a configuration, it is possible to transfer the substrate on thefirst delivery stage to the process block where processing can becarried out earliest. Accordingly, the total processing time can bereduced, and throughput can be improved.

Here, the substrate processing apparatus may be configured such that aninterface portion to which a light exposure device is connected isconnected to a side of the transfer path opposite to a side connected tothe carrier block, or may be configured such that the interface portionto which the light exposure device is connected is connected to a sideof the transfer path opposite to a side connected to the process blocks.

Further, the process block includes a coating unit for applying a resistsolution to the substrate, a developing unit for performing developingprocessing on the substrate after exposure to light, a heating unit forheating the substrate, the third transfer means for transferring thesubstrate between the units, and the second delivery stage forperforming delivery of the substrate between the second transfer meansand the third transfer means, and such application of the resistsolution and/or the developing processing after exposure to light isperformed on the substrate in units of each process block. At this time,the process block control portion may be configured to further have afunction to select the coating unit, the developing unit and the heatingunit for use in the processing, based on the process recipe of thesubstrate.

Each process block may include a liquid process unit performingprocessing on the substrate using a chemical solution, a heating unitfor heating the substrate, the third transfer means for transferring thesubstrate between the units, and the second delivery stage forperforming delivery of the substrate between the second transfer meansand the third transfer means, and it may be configured such that aseries of processing are performed on the substrate in units of eachprocess block. At this time, the process block control portion may beconfigured to further have a function to select the liquid process unitand the heating unit for use in the processing, based on the processrecipe of the substrate.

Further, the liquid process unit may be for forming a coating film, orfor coating the substrate with a chemical solution containing aprecursor of an insulating film. Furthermore, the plurality of processblocks are formed to have the same size in two dimensions. The secondtransfer means is provided at a transfer block that extends alongarrangement of the plurality of process blocks, and each process blockis configured to be attachable to and detachable from the transferblock.

EFFECTS OF THE INVENTION

According to the substrate processing apparatus of the presentinvention, it is possible to reduce the total processing time andimprove the throughput by transferring the substrate on the firstdelivery stage to the process block where processing can be carried outearliest.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a top plan view showing a substrate processing apparatusaccording to an embodiment of the present invention.

FIG. 2 is a perspective view showing the substrate processing apparatusaccording to the embodiment of the present invention.

FIG. 3 is a side cross sectional view of the substrate processingapparatus.

FIG. 4 is a side cross sectional view of the substrate processingapparatus.

FIG. 5 is a perspective view showing the interior of the process blockof the substrate processing apparatus.

FIG. 6 is a cross sectional view of a coating unit provided in thesubstrate processing apparatus.

FIG. 7 is a cross sectional view of a heating unit (PEB) provided in thesubstrate processing apparatus.

FIG. 8 is a perspective view of third transfer means provided in thesubstrate processing apparatus.

FIG. 9 is a block diagram illustrating a control system of the substrateprocessing apparatus of the present invention.

FIG. 10 is a top plan view illustrating functions of the substrateprocessing apparatus of the present invention.

FIG. 11 is a top plan view illustrating another embodiment of thesubstrate processing apparatus of the present invention.

FIG. 12 is a side cross sectional view of the substrate processingapparatus.

FIG. 13 is a side cross sectional view of the substrate processingapparatus.

FIG. 14 is a top plan view illustrating another embodiment of thesubstrate processing apparatus of the present invention.

FIG. 15A is a top plan view illustrating another embodiment of thesubstrate processing apparatus of the present invention.

FIG. 15B is a top plan view illustrating the other embodiment of thesubstrate processing apparatus of the present invention.

FIG. 16 is a top plan view illustrating a conventional substrateprocessing apparatus.

FIG. 17 is a top plan view illustrating another embodiment of thesubstrate processing apparatus of the present invention.

DESCRIPTION OF THE REFERENCE SIGNS

B1: carrier block; B2: transfer block; B3: first process block; B4:second process block; B5: third process block; B6: interface portion;B7: light exposure device; C: substrate carrier; 22: first transfermeans; 23: second transfer means; 24: first delivery stage; 31: thirdtransfer means; 32: coating unit; 33: developing unit; 81: systemcontrol portion; 82A-82C: process block control portions; and 83:transfer block control portion.

BEST MODES FOR CARRYING OUT THE INVENTION

Hereinafter, an embodiment of a substrate processing apparatus of thepresent invention will be described. FIG. 1 is a top plan view showingan overall configuration according to an embodiment of the substrateprocessing apparatus, and FIG. 2 is a schematic perspective view thereofIn the figures, B1 is a carrier block for loading/unloading a substratecarrier C containing, e.g., 25 substrates, such as semiconductor wafersW. Carrier block B1 includes a carrier placement portion 21 forplacement of substrate carrier C, and first transfer means 22.

On one side of carrier block B1, for example on the left end side asseen from the carrier placement portion 21 side, a transfer block B2having a transfer path linearly extending in the lateral direction,i.e., the direction approximately orthogonal to the arrangementdirection of carriers C, is provided to be connected to carrier blockB1. First transfer means 22 of carrier block B1 is configured to bemovable left and right, back and forth, up and down and also rotatableabout a vertical axis so as to take out wafer W from substrate carrier Cand deliver the relevant wafer W to second transfer means 23 of transferblock B2.

Here, a first delivery stage 24 is provided at carrier block B1 in thevicinity of the region connected to transfer block B2, for deliveringwafer W between first transfer means 22 of carrier block B1 and secondtransfer means 23 of transfer block B2. This delivery stage 24 isconfigured, e.g., in two stages of: a delivery stage for loading, foruse in loading wafer W to transfer block B2; and a delivery stage forunloading, for use in unloading wafer W from transfer block B2. It isnoted that delivery stage 24 may be provided in transfer block B2 in aregion accessible by first transfer means 22. Alternatively, it may beconfigured in one stage so that a common delivery stage can be used forloading/unloading wafer W with respect to transfer block B2. Forexample, the delivery stage has a structure capable of supporting threesubstrates at the back surfaces, and is configured not to interfere withthe respective arms of first and second transfer means 22 and 23.

Transfer block B2 is provided with a guide rail 25 that constitutes thetransfer path linearly extending in the lateral direction. Secondtransfer means 23 is provided with two arms for holding the wafers, forexample, and is configured to be movable in the lateral direction alongguide rail 25, movable up and down, movable back and forth, androtatable about a vertical axis. It is noted that transfer means 23 mayhave a single arm.

Further, a plurality of, e.g., three process blocks B3, B4, B5 areprovided in a freely attachable/detachable manner with respect totransfer block B2 constituting the main body of the apparatus, which arearranged along the transfer path of transfer block B2. In this example,first through third process blocks B3-B5 are identical to each other inconfiguration, with their parts arranged in identical layout. That is,process blocks B3-B5 are formed to have the same size, and the equalnumbers of identical types of process units are arranged in processblocks B3-B5 in the same layout.

Specifically, taking first process block B3 as a representative andreferring also to FIGS. 3-5, third transfer means 31 is provided at thecenter of process block B3, and to surround the same, for example, aliquid process unit group U1 having for example three coating-relatedunits (COT) 32 and two developing units (DEV) 33 stacked in multiplestages, e.g., in five stages, is arranged to the right as seen fromcarrier block B1 to the back, and shelf units U2 and U3 having multiplestages, e.g., six stages and ten stages, respectively, of units relatedto heating/cooling or the like, are arranged on the front side and theback side, respectively, to the left.

Coating-related unit 32 and developing unit 33 each constitute theliquid process unit. Coating-related unit 32 may include, for example, acoating unit for performing processing of coating wafer W with a resistsolution, and an anti-reflection coating forming unit for forming alower-layer anti-reflection coating or an upper-layer anti-reflectioncoating by applying a chemical solution for formation of anti-reflectioncoating to the wafer surface before or after application of the resistsolution. Developing unit 33 is a unit for performing developingprocessing by, e.g., forming a puddle of a developing solution on thesubstrate after exposure to light and keeping the same in that state fora prescribed period of time.

Shelf units U2, U3 are each configured by stacking a plurality of unitsat the region accessible by second transfer means 23 of transfer blockB2. In this example, there are provided for example three vacuum dryingunits (VD) for removing solvent included in the coating solution afterthe liquid processing performed at the coating unit, the anti-reflectioncoating forming unit and the like, for example four heating units (LHP)for use in prescribed heating processing of wafer W before coating withthe resist solution or for use in heating processing after development,for example one heating unit (PAB), called a pre-baking unit or thelike, for performing heating processing on the wafer after coating withthe resist solution, for example two heating units (PEB), called apost-exposure baking unit or the like, for performing heating processingon the wafer W after exposure to light, for example three temperatureregulating units (CPL) that are units for adjusting wafer W to aprescribed temperature, a hydrophobic process unit (ADH) for performinghydrophobic processing on the wafer surface, and additionally, forexample one delivery unit (TRS1) for loading wafer W to process blockB3, and for example one delivery unit (TRS2) for unloading wafer W fromprocess block B3, which are allocated in a vertical direction.

Delivery units TRS1, TRS2 correspond to the second delivery stage of thepresent invention. Although FIGS. 3-5 show an example of the layout ofthese units, the number and the types of the units are not limitedthereto, and in this example as well, it may be configured to have asingle delivery unit to be used for both loading of wafer W to processblock B3 and unloading of wafer W from process block B3. Further, thedelivery unit (TRS2) may be added with a temperature regulating functionfor the purpose of lowering the temperature of the wafer, and it may beconfigured such that this temperature regulating function is used tolower the temperature of wafer W when delivering the same after theprocessing in the heating unit (PAB), or after the heating processingfollowing the developing processing, for example.

Third transfer means 31 is configured to be movable up and down, backand forth, and also rotatable about a vertical axis, as will bedescribed later, and is responsible for transferring wafer W betweenliquid process unit group U1 and shelf units U2, U3. It is noted thatsecond transfer means 23 is not shown in FIG. 2 for the sake ofconvenience. Second transfer means 23 is configured as described above,so as to deliver wafer W received from first transfer means 22 todelivery unit TRS1 (TRS2) of process block B3.

Further, in this example, at each of the upper side of transfer block B2and the upper side of the region of process block B3 where thirdtransfer means 31 is provided, a fan filter unit (FFU) 35 formed with afan having rotary blades and a ULPA filter or a chemical filter isprovided. The cleaned air having particles and ammonia componentsremoved by fan filter unit 35 is supplied to the lower side of transferblock B2 and to the lower side of the region where third transfer means31 is provided. Further, at each of the upper side of the region inprocess block B3 where shelf units U2, U3 are provided, and the upperside of the region in process block B3 where liquid process unit groupU1 is provided, an electric equipment storing portion 36 is provided, inwhich a driver connected to a motor of transfer means or the like, anI/O board connected to each unit, and a control portion for controllingeach unit are stored.

A chemical unit U4 storing tanks of chemical solutions such as adeveloping solution and a coating solution including an anti-reflectioncoating forming solution, a liquid for temperature regulation, adeveloping solution, inactive gas and others, is provided near the floorsurface on the lower side of liquid process unit group U1, and near thefloor surface on the lower side of shelf units U2, U3, a first utilityunit U5 containing a plurality of utility lines for taking in utilitiesfrom the outside is provided. Meanwhile, transfer block B2 is providedwith a second utility unit U6 of the external side, corresponding tofirst utility unit U5. It is configured such that first and secondutility units U5, U6 are connected to each other when process block B3is pressed to the transfer block B2 side.

The side of third process block B5 opposite to the first process blockB3 side is connected via an interface portion B6 to a light exposuredevice B7. Further, interface portion B6 is set to be connected to theside of transfer block B2 opposite to the side connected to carrierblock B1. Interface portion B6 is provided with delivery means 26, whichis configured to be movable up and down, left and right, back and forth,and also rotatable about a vertical axis, for example, so as to deliverwafer W between second transfer means 23 of transfer block B2 and lightexposure device B7. Here, at interface portion B6, in the vicinity ofthe region connected to transfer block B2, a delivery stage 27 formed intwo stages for example is provided for delivering wafer W betweendelivery means 26 of interface portion B6 and transfer means 23 oftransfer block B2. Delivery stage 27 may be provided in transfer blockB2 in the region accessible by second transfer means 23 and by deliverymeans 26 of interface portion B6, or it may be provided with atemperature regulating mechanism for keeping the substrate temperatureuniform. Further, it may be configured with one stage or more than onestage.

Hereinafter, configurations of coating-related unit 32, the heating unit(PEB) and others provided at process blocks B3-B5 will be described inbrief. Firstly, coating-related unit 32 such as the coating unit or theanti-reflection coating forming unit is described with reference to FIG.6. Although the coating-related unit used may have a configuration of aspin coating type where a processing solution is supplied onto thesubstrate and spread by rotation as will be described later, herein, ascanning coating device is described by way of example.

Wafer W is partially notched at its peripheral portion to provide anotch N indicating the direction of wafer W. In the figure, 51represents a substrate holding portion, which is configured with anattraction portion 51 a that attracts the back surface side of wafer Wto hold it approximately horizontally, and a drive base body 52, movablein the X direction, that causes attraction portion 51 a to be movable upand down and rotatable about a vertical axis. Drive base body 52 has itsbottom end supported by a movable body 53.

A ball screw portion 54 is provided near the bottom surface of movablebody 53, which portion is driven by a motor M1. When ball screw portion54 is rotated by motor M1, movable body 53 is guided by a rail notshown, to move in the Y direction in the figure. Further, a rail notshown is provided on the upper surface of movable body 53 to guide drivebase body 52 in the X direction. With the operations of drive base body52 and movable body 53, wafer W held by substrate holding portion 51 ismovable to any position in the X and Y directions, respectively. Bymeans of movable body 53, the rails not shown, ball screw portion 54 andmotor M1, wafer W is moved back and forth relative to a coating solutionnozzle 55 provided on the upper side of wafer W for applying the coatingsolution such as the resist solution or the chemical solution for theanti-reflection coating. That is, wafer W is moved in the Y axisdirection in FIG. 6.

Coating solution nozzle 55 is configured to be movable in the Xdirection by means of a drive base body 56 of a rectangular shapeextending in the X direction, which contains therein a drive pulley, adriven pulley, an endless belt wound around the pulleys, which are notshown, and a motor M2 for rotating the drive pulley. In the FIG. 57 (57a, 57 b) represents a pair of liquid receiving portions for receivingthe coating solution dropping from the above to prevent the coatingsolution from being fed to the region of wafer W near the outerperiphery.

In this coating-related unit 32, when coating solution nozzle 55 movesfrom one end face to the other end face of the wafer, wafer W is movedintermittently, at the corresponding timing, in the direction crossingthe same. With repetition of such an operation, the coating solution isapplied onto wafer W as if drawing a picture without lifting the pencilfrom the paper.

The vacuum drying unit (VD), which is the process unit for use in thestep following that of coating-related unit 32, is configured to heatwafer W to a prescribed temperature while reducing the pressure to aprescribed degree of vacuum in a sealed vessel, for example, to vaporizea solvent within the coating film to thereby form the coating film.Further, developing unit 33 is configured to supply a developingsolution from the supply nozzle to the central portion of wafer W alongthe width in the radial direction of wafer W, to cause wafer W to halfturn to create a puddle of the developing solution on wafer W, and tocarry out prescribed developing processing by leaving wafer W with thepuddle of the developing solution thereon for a prescribed period oftime.

A post exposure baking unit (PEB) serving as the heating unit will nowbe described with reference to FIG. 7. In a casing 6, on an uppersurface of a stage 60, a cooling plate 61 is arranged on the front side,and a heating plate 62 provided with a heater 62 a is arranged on theback side. Cooling plate 61 is used to deliver wafer W between heatingplate 62 and third transfer means 31 that advances into casing 6 via anopening portion 63 provided with a shutter 63 a, and also functions tocool the heated wafer W to some extent (rough heat removal) at the timeof transfer. Thus, as shown in the figure, a leg portion 61 a isconfigured to be movable back and forth in the Y direction along guidemeans not shown, so that cooling plate 61 can move from the position onthe side of opening portion 63 to the position above heating plate 62.Further, a cooling flow channel not shown is provided on the rearsurface side of cooling plate 61.

In stage 60, at the delivery position of wafer W between third transfermeans 31 and cooling plate 61, and at the delivery position of wafer Wbetween heating plate 62 and cooling plate 61, support pins 64 areprovided, which protrude and retreat freely. Cooling plate 61 isprovided with slits not shown, to allow raised support pins 64 topenetrate through cooling plate 61 to lift wafer W. In the figure, 66represents a ventilation room in communication via a fan 66 a, and 67represents a ventilation hole provided with a fan 67 a.

In such a heating unit (PEB), wafer W is delivered from third transfermeans 31 onto cooling plate 61, and then delivered by cooling plate 61onto heating plate 62, where prescribed heating processing is carriedout. The wafer having undergone the heating processing is returned fromheating plate 62 to cooling plate 61, where it is cooled to some extent,and then received by the third transfer means to be transferred to thenext step.

The heating units (LHP), (PAB) each have a configuration provided withonly a heating plate for heating wafer W to a prescribed temperature,and temperature regulating unit (CPL) has a configuration provided withonly a cooling plate for adjusting wafer W to a prescribed temperature.

Third transfer means 31 will now be described with reference to FIG. 8.This transfer means 31 is provided with for example three arms 71 forholding wafers W, a base table 72 supporting arms 71 to be freelymovable back and forth, a pair of guiding rails 73 a, 73 b supportingbase table 72 to be freely movable up and down, connecting members 74 a,74 b respectively connecting the upper ends and lower ends of guidingrails 73 a, 73 b, a rotation drive portion 75 integrally attached toconnecting member 74 b at the lower ends of the guiding rails so as todrive a frame body made of guiding rails 73 a, 73 b and connectingmembers 74 a, 74 b in a manner rotatable about a vertical axis, and arotation shaft portion 76 provided at connecting member 74 a at theupper ends of the guiding rails.

Arm 71 is configured with three stages so as to respectively hold wafersW, and has its proximal end portion movable in a sliding manner alongthe longitudinal direction of the base table. Such back and forthmovement of arm 71 by sliding is controlled by drive means not shown.Further, the up and down movement of base table 72 is controlled byanother drive means not shown. In this manner, arm 71 is driven to berotatable about the vertical axis as well as movable up and down andback and forth.

In such a substrate processing apparatus, as shown in FIGS. 1 and 9, theentire apparatus is controlled by a system control portion 81, andprocess blocks B3-B5 are controlled by process block control portions 82(82A-82C), respectively, based on instructions from system controlportion 81. Transfer block B2 is controlled by a transfer block controlportion 83, based on an instruction from system control portion 81.System control portion 81 includes a recipe storing portion 81 a thatstores a recipe of processing carried out in process blocks B3-B5 foreach substrate contained in a substrate carrier, for example, a recipemaking portion 81 b that modifies or edits the recipe, and a recipeselecting portion 81 c that selects a prescribed recipe from among theplurality of recipes stored in the recipe storing portion.

Process block control portion 82A (82B, 82C) includes a first program 82a that controls process unit B3 (B4, B5), based on a prescribed recipetransmitted from system control unit 81, to select a process unitrequired for the processing of the relevant recipe, and to perform theprocessing under predetermined process conditions, and a second program82 b that keeps track of the processed state of the wafer inside processblock B3 (B4, B5) for output to system control portion 81. As such, inprocess block control portion 82A (82B, 82C), the processed state of thewafer within process block B3 (B4, B5) is recognized in real time andinformed to system control portion 81. Thus, in system control portion81, it is possible to understand in which process unit the last wafer Wis being processed in each of process blocks B3-B5, and which one ofprocess blocks B3-B5 can finish processing of wafer W earliest in theprocess unit in the final process step.

Transfer block control portion 83 includes control means for controllingthe second transfer means, and stores a transfer program 83 a fortransferring wafer W delivered by second transfer means 23 between firstdelivery stage 24 and delivery units TRS1, TRS2 of prescribed processblocks B3-B5 and delivery stage 27 of interface portion B6, based oninstructions from system control portion 81.

The flow of the wafers in such a substrate processing apparatus will nowbe described in brief. An automatic transfer robot (or an operator)loads carrier C storing 25 wafers W, for example, from the outside ontocarrier placement portion 21 of carrier block B1. Next, first transfermeans 22 takes out wafer W from within carrier C and delivers the sameto delivery stage 24 of carrier block B1. Wafer W on delivery stage 24is delivered by second transfer means 23 of transfer block B2 to apredetermined process block, e.g., first process block B3, via deliveryunit TRS1 for use in input of the relevant process block B3. In processblock B3, third transfer means 31 transfers the wafer to prescribedprocess units successively, to perform, e.g., the resist solutioncoating process in this example in units of the block.

Wafer W coated with the resist solution is delivered to second transfermeans 23 of transfer block B2 via delivery unit TRS2 for use in output,and transferred to delivery stage 27 of interface portion B6.Thereafter, wafer W is transferred by delivery means 26 of interfaceportion B6 to light exposure device B7, where prescribed light exposureprocessing is carried out.

Wafer W having been exposed to light is transferred via delivery means26 of interface portion B6, delivery stage 27, and second transfer means23 of transfer block B2, back to the original process block where theresist solution was applied, i.e., to first process block B3 viadelivery unit TRS1 for use in input provided at process block B3. It isthen transferred by third transfer means 31 to a predetermined processunit, where prescribed developing processing, for example, is carriedout. Thereafter, it is delivered to second transfer means 23 of transferblock B2 via delivery unit TRS2 for use in output. It is then returnedto original carrier C, for example, via delivery stage 24 of carrierblock B1 and first transfer means 22. Thus, in this example, formationof coating film of one kind is carried out in units of blocks in firstthrough third process blocks B3-B5, and formation of the coating film iscompleted in the respective process blocks B3-B5.

A characteristic configuration of the present invention will now bedescribed with reference to FIG. 10. Here, the case of transferring thesubstrates in a plurality of substrate lots allocated in accordance withthe kinds of the wafers will be explained, assuming that two wafers WAof the kind A are stored in first process block B3, two wafers WB of thekind B are stored in second process block B4, two wafers WC of the kindC are stored in third process block B5, and a wafer WD of the kind D issupposed to be discharged from carrier C. It is noted that a pluralityof lots may be allocated in the same substrate carrier, as in the casewhere wafers to be subjected to different kinds of processing arecontained in the same substrate carrier C, or the respective lots may beallocated in different substrate carriers C.

Process block control portions 82A-82C of respective process blocksB3-B5 keep track of the processed states of wafers WA-WC in therespective blocks B3-B5, and send the information to system controlportion 81 in real time. As such, system control portion 81 recognizeshow far the processing has proceeded for the last wafers WA-WC, viaprocess block control portions 82A-82C.

Meanwhile, the first wafer WD of the succeeding lot is discharged fromcarrier C by first transfer means 22 and transferred to first deliverystage 24. Second transfer means 23 of transfer block B2 is driven basedon a transfer program of transfer block control portion 83. When it isabout to pick up wafer WD on delivery stage 24 at a timing determined bythe transfer program, it makes an inquiry to system control portion 81as to which process block B3-B5 the wafer should be transferred.

System control portion 81 determines unoccupied states of process blocksB3-B5 and issues an instruction to transfer block control portion 83 totransfer wafer WD to process block B3-B5 determined to be unoccupied.Herein, the unoccupied process block B3-B5 not only refers to theprocess block B3-B5 where the last wafer W of the preceding substratelot does not exist, but also refers to the process block B3-B5 where thefinal process step for the last wafer W in the relevant process blockB3-B5 will be finished earliest.

In this manner, process block B3-B5 in which the processing of thewafers within process block B3-B5 will be finished earliest isdetermined based on the processing information of wafers WA-WC in therespective process blocks B3-B5, before the first wafer WD of thesucceeding lot is delivered from first delivery stage 24 to secondtransfer means 23. This information is sent to transfer block controlportion 83, and wafer WD is transferred to the determined process blockB3-B5 by second transfer means 23. Here, for wafer WD, a recipe of theprocessing to be performed on the relevant wafer WD is stored in systemcontrol portion 81, and once the process block B3 (B4, B5) to whichwafer WD is to be transferred is determined, the process recipe of therelevant wafer WD is transmitted from system control portion 81 toprocess block control portion 82A (82B, 82C) of the relevant processblock B3 (B4, B5). In the process block B3 (B4, B5), the process unitsto be used are selected based on the process recipe, and processing isperformed in each of the process units under predetermined processingconditions.

Wafer W following the relevant wafer WD is transferred to predeterminedprocess block B3-B5 in a similar manner, to be subjected topredetermined processing. Although the case of transferring a firstwafer in a different lot has been described here by way of example, inthe case of transferring a wafer of the same lot as well, process blockB3-B5 is selected in a similar manner for performing predeterminedprocessing.

Hereinafter, a specific example of wafer processing carried out in eachprocess block B3-B5 will be described, assuming that wafer WA to besubjected to first processing, wafer WB to be subjected to secondprocessing, and wafer WC to be subjected to third processing are storedin the same substrate carrier C, for example. In this example, the firstprocessing refers to formation of anti-reflection coatings on alower-layer side and an upper-layer side, respectively, of a resist filmwith respect to the wafer, the second processing refers to formation ofan anti-reflection coating on an upper-layer side of a resist film withrespect to the wafer, and the third processing refers to formation of ananti-reflection coating on a lower-layer side of a resist film withrespect to the wafer.

In the case where the wafer within carrier C is wafer WA to be subjectedto the first processing, when the process block to which the relevantwafer WA is to be transferred is determined to be first process blockB3, for example, the process recipe of wafer WA is transmitted fromsystem control portion 81 to process block control portion 82A of therelevant process block B3. As described above, in process block controlportion 82A, the process units for use are selected based on the processrecipe, and processing is performed in each of the process units underpredetermined processing conditions. More specifically, in the firstprocessing, wafer WA firstly carried in via delivery unit TRS1 istransferred in the order of a temperature regulating unit (CPL)→acoating-related unit (COT) for formation of the anti-reflection coatingon the lower-layer side→heating unit (LHP) or a vacuum drying unit(VD)→temperature regulating unit (CPL)→coating unit (COT)→heating unit(PAB) or vacuum drying unit (VD)→temperature regulating unit (CPL)→anupper-layer anti-reflection coating forming unit (COT)→heating unit(LHP) or vacuum drying unit (VD), during which the anti-reflectioncoating on the lower-layer side (Bottom-ARC), the film of the resistsolution, and the anti-reflection coating on the upper-layer side(Top-ARC) are formed in this order from the lower side, and then carriedout via delivery unit TRS2 to be subjected to light exposure processingat light exposure device B7. Here, the next step of that ofcoating-related unit (COT) may be performed using either heating unit(LHP, PAB) of hot plate type or vacuum drying unit (VD).

Next, wafer WA having been exposed to light is transferred through theabove-described path to the original process block B3 where the resistsolution was applied, via a delivery unit TRS1 for use in input of therelevant process block. It is transferred through heating unit(PEB)→temperature regulating unit (CPL)→developing unit (DEV), wherepredetermined developing processing is performed. It is then adjusted toa predetermined temperature in heating unit (LHP), and carried out viadelivery unit TRS2. The first processing for forming the lower-layeranti-reflection coating, the resist film and the upper-layeranti-reflection coating is carried out in this manner. Thus, in theprocess block to which wafer WA to be subjected to the first processingis transferred, the above-described process units are selected, andpredetermined processing is carried out in each process unit.

In the case where the wafer within carrier C is wafer WB to be subjectedto the second processing, when the process block to which the relevantwafer WB is to be transferred is determined to be second process blockB4, for example, a process recipe of wafer WB is transmitted from systemcontrol portion 81 to process block control portion 82B of this processblock B4. In process block control portion 82B, the process units foruse are selected based on the process recipe, as described above, andprocessing is carried out under predetermined processing conditions ineach of the process units. More specifically, in the second processing,the wafer is transferred in the order of a hydrophobic process unit(ADH)→temperature regulating unit (CPL) →coating unit (COT)→vacuumdrying unit (VD) to perform coating processing of a resist solution, andthen transferred in the order of heating unit (PAB)→temperatureregulating unit (CPL)→upper-layer anti-reflection coating forming unit(COT) →vacuum drying unit (VD)→heating unit (LHP), to form theupper-layer anti-reflection coating (Top-ARC). Thereafter, it istransferred to light exposure device B7, as described above, wherepredetermined light exposure processing is carried out.

Next, wafer WB having been exposed to light is transferred to processblock B4 where application of the resist solution and formation of theupper-layer anti-reflection coating were conducted, through theabove-described path. Predetermined developing processing is conductedin a similar manner as in the first processing above, and thus, theresist film and the upper-layer anti-reflection coating are formed. Assuch, in the process block to which wafer WB to be subjected to thesecond processing is transferred, the above-described process units areselected, and predetermined processing is carried out in each of theprocess units.

Further, in the case where the wafer within carrier C is wafer WC to besubjected to the third processing, when the process block to which waferWC is to be transferred is determined to be third process block B5, forexample, a process recipe of wafer WC is transmitted from system controlportion 81 to process block control portion 82C of this process blockB5. In process block control portion 82C, the process units for use areselected based on this process recipe, and processing is carried out ineach of the process units under prescribed processing conditions. Morespecifically, in the third processing, the wafer is transferred in theorder of temperature regulating unit (CPL)→lower-layer anti-reflectioncoating forming unit (COT) →vacuum drying unit (VD)→heating unit (LHP),for example, to form the lower-layer anti-reflection coating, and thentransferred in the order of temperature regulating unit (CPL)→coatingunit (COT)→vacuum drying unit (VD)→heating unit (PAB), to conduct thecoating processing of the resist solution. Thereafter, it is transferredto light exposure device B7, as described above, to be subjected topredetermined light exposure processing.

Next, wafer WC having been exposed to light is transferred to processblock B5 where application of the resist solution and formation of thelower-layer anti-reflection coating were performed, through the pathsimilar to those in the first and second processing described above, tobe subjected to predetermined developing processing. The lower-layeranti-reflection coating and the resist film are formed in this manner.As such, in process block B5 to which wafer WC to be subjected to thethird processing is transferred, the above-described process units areselected, and predetermined processing is carried out in each of theprocess units.

As described above, in the present embodiment, different kinds ofprocessing are performed in the respective process blocks B3-B5. It isnoted that two different recipes would not be carried out simultaneouslywithin one process block. Rather, one kind of processing is carried outonly after the other kind of processing is finished.

In this configuration, transfer block B2 is provided, and secondtransfer means 23 of the relevant transfer block B2 performs delivery ofwafers W between carrier block B1 and respective process blocks B3-B5,and between respective process blocks B3-B5 and interface portion B6.Further, in the respective process blocks B3-B5, parallel processing iscarried out for each block. This means that third transfer means 31 ofeach process block B3-B5 only needs to take charge of transfer of waferW within the relevant process block B3-B5, so that the burden oftransfer means 31 is alleviated compared to the conventional case. Assuch, it is less probable that transfer of processed wafer W by transfermeans 31 is awaited, which leads to reduction in transfer time and,hence, improvement in throughput when seen as the entire apparatus.

Further, each process block B3-B5 is configured to be freely attachableto and detachable from transfer block B2 (main body of the apparatus),and a series of processing of different kinds are completed in units ofthe process blocks. Thus, for example in the case of increasing the kindof processing, it can be addressed by adding a process blockcorresponding to that new kind of processing, ensuring a large degree offreedom in processing carried out in the apparatus. As such, it isapplicable to production in small amount for various kinds, as in thecase where wafers to be subjected to different kinds of processing aremounted in the same carrier C, as described in the above embodiment.

Furthermore, in each of the first through third process blocks B3-B5, aseries of processing are carried out independently for each block.Further, when wafer W is discharged from substrate carrier C onto firstdelivery stage 24 and second transfer means 23 of transfer block B2 isto pick up this wafer W, the processed states of wafers W within firstthrough third process blocks B3-B5 are confirmed, and the process blockwhere there is no wafer W or the processing will be finished earliest ischecked, and second transfer means 32 is controlled to transfer wafer Wto the relevant process block. This enables smooth transfer of wafer Wfrom first delivery stage 24 to the process block.

That is, in the conventional case, when there is more than one processblock, a series of processing are carried out by all the process blocksas a whole. This poses the problem, as described in the background artsection, that when wafer WB requiring short processing time isdischarged after wafer WA requiring long processing time, wafer WB wouldcatch up with wafer WA in a certain step, hindering smooth transfer ofwafer WB, which leads to degradation of throughput. In contrast, withthe configuration of the present invention, a series of processing arecarried out independently in each of the process blocks, and theprocessed state of the last wafer W in each process block variesdepending on the timing of transferring wafer W to the process block, orthe kind of the processing. Accordingly, it is configured such that theprocessed states of wafers W in the respective process blocks are kepttrack, and the process block to which newly discharged wafer W is to betransferred is determined in accordance with the unoccupied state(s) ofthe process block(s) at the timing of transferring the relevant wafer W.This can shorten the standby time of wafer W on first delivery stage 24to the greatest extent, whereby smooth transfer of wafer W to theprocess block is ensured. Accordingly, the total transfer time isreduced, and throughput for the entire processing is increased.

At this time, in the case of production of various kinds with smallquantities, such as when wafers to be subjected to different kinds ofprocessing are stored in a substrate carrier C, and in the case wherewafer WA belonging to the first group of kind of processing isdischarged before discharge of wafer WB belonging to the second group ofkind of processing for which the processing time is shorter than that ofthe first kind of processing, the destination of the wafer is determinedbased on the states of the process blocks that are known in advance.This can suppress occurrence of the state where succeeding wafer WBcatches up with preceding wafer WA during the processing, causing waferWB to be awaited to be transferred to the next step. Thus, degradationin throughput can be suppressed advantageously.

Further, the process units of the numbers corresponding to the presetprocessing are prepared in each process block, including coating-relatedunit 32, developing unit 33, vacuum drying unit (VD), heating unit (PEB,PAB, LHP), hydrophobic process unit (ADH), temperature regulating unit(CPL) or the like, and, in accordance with a process recipe of waferstransferred to the relevant process block, process block control portion82 selects coating-related unit 32, developing unit 33, heating unit andother processing units corresponding to the relevant recipe, and setsthe processing conditions to perform predetermined processing. In thismanner, different kinds of processing can be performed by one processblock, whereby the degree of freedom in processing performed by theapparatus can be increased.

Further, it is configured such that the process units in the processblock are combined freely to perform processing, as described above, sothat system control portion 81 as well as process block control portions82A-82C can store a program with which in the event that there is atrouble such as breakdown of a process unit within a process block, thewafer is transferred to another process unit. In doing so, it becomesunnecessary to immediately stop the processing upon occurrence of such atrouble to check or exchange the relevant process unit in trouble,whereby degradation in throughput can be suppressed.

Still further, in this example, creation of the process recipe andtransfer recipe of wafers can be simplified. That is, in theconventional apparatus, the process recipe of the wafers would designatenot only the process flow, but also the process units themselves to beused therein, as described above. In contrast, with the method of thepresent invention, the process recipe of wafers W managed by systemcontrol portion 81 designates the process flow alone. It is onlynecessary to determine the process unit to be used before secondtransfer means 23 receives wafer W on first delivery stage 24. It isthus unnecessary to designate the process unit to be used in the processrecipe, whereby creation of the process recipe and the transfer recipeis simplified.

In the present embodiment, the case of performing different kinds ofprocessing in first through third process blocks B3-B5 has beenexplained. Alternatively, each of first through third process blocksB3-B5 may conduct the same kind of processing, or two of first throughthird process blocks B3-B5 may conduct the same kind of processing whilethe remaining process block conducts a different kind of processing.Further, in the case where processing is to be conducted using the samekinds of process units in each of first through third process blocksB3-B5, only the required process units may be mounted in each of processblocks B3-B5, in which case, the first program of the process blockcontrol portion only needs to be provided with the function to controlthe operations of the third transfer means and the respective processunits such that predetermined processing is carried out based on apredetermined recipe with respect to the substrates in the processblock.

Hereinafter, another example of the substrate processing apparatus ofthe present invention will be described with reference to FIGS. 11-13.The substrate processing apparatus of this example differs from theabove example only in the inner configuration of first through thirdprocess blocks B3-B5. These process blocks B3-B5 are formed to have thesame size and the same layout of process units arranged therein.

More specifically, on the front side as seen from carrier block B1, twoliquid process unit groups 91A, 91B each having liquid process-relatedprocess units in multiple stages, e.g., five stages, are provided, andon the back side thereof, two shelf units 93A, 93B each havingheating/cooling-related process units in multiple stages, e.g., tenstages and six stages, respectively, are provided, with third transfermeans 92 sandwiched therebetween. Third transfer means 92 deliverswafers W between liquid process unit groups 91A, 91B and shelf units93A, 93B. Further, shelf unit 93A on the transfer block B2 side isprovided with a delivery unit (TRS1, TRS2) at the position accessible bysecond transfer means 23 of transfer block B2, serving as the deliverystage for delivering wafers W between second transfer means 23 and thirdtransfer means 92.

As such, in each of process blocks B3-B5, as in the case of, e.g., theabove embodiment, for example three coating-related units (COT) 32, twodeveloping units (DEV) 33, three vacuum drying units (VD), four heatingunits (LHP), one heating unit for pre-baking (PAB), two heating units(PEB) for post-exposure baking, three temperature regulating units(CPL), one hydrophobic process unit (ADH), and additionally, twodelivery units (TRS1, TRS2) are provided.

In this example, as in the case of the above embodiment, a series ofprocessing are completed in units of the process blocks, and theprocessed states of wafers W in the respective process blocks are kepttrack. Second transfer means 23 transfers wafer W on first deliverystage 24 to the process block in which the last wafer W does not existor in which the final step for the last wafer W will be finishedearliest.

Further, the substrate processing apparatus of the present invention isnot limited to the configuration where light exposure device B7 isconnected via interface portion B6 to the side of transfer block B2opposite to the side connected to carrier block B1. It may be configuredas shown in FIG. 14, for example, such that light exposure device B7 isconnected via interface portion B6 to the side of transfer block B2opposite to the side connected to process blocks B3-B5. In this case, asshown in FIG. 14 for example, interface portion B6 is provided with adelivery stage 95 for delivering wafers W between second transfer means23 of transfer block B2 and delivery means 94 of interface portion B6.Here, the layout in each process block may be as shown in FIG. 1, or asshown in FIG. 10.

The coating-related unit of the present invention is not limited to theabove-described device shown in FIG. 6. It may be configured such thatwafer W is placed on a substrate holding portion that holds the samerotatably around a vertical axis, and a coating solution is suppliedfrom a coating solution nozzle provided near the center of rotation ofwafer W while rotating wafer W, to cause the coating solution to spreadon the wafer surface by centrifugal force of rotation. In this case, thevacuum drying step following application of the coating solution isunnecessary, so that it is preferable that the process block is mountedwith a heating unit (LHP) or other unit instead of the vacuum dryingunit (VD).

Further, in the present invention, besides the configuration where thelight exposure device is connected to the process block(s), the lightexposure device may be separated from the process block(s) and providedat a different location. In this case, wafer W in carrier C of carrierblock B1 is transferred via first transfer means 22 and second transfermeans 23 to a prescribed process block to be subjected to resistsolution coating processing, for example, and then returned to carrierblock B1 again via second transfer means 23 and first transfer means 22,and thereafter, the relevant wafer W is transferred to the lightexposure device arranged at the different location to be subjected toprescribed light exposure processing. Wafer W having undergone the lightexposure processing is returned via carrier block B1, first transfermeans 22 and second transfer means 23 to the original process blockwhere the resist solution was applied, and prescribed developingprocessing is carried out therein. It is then again returned via secondtransfer means 23 and first transfer means 22 to the original carrier Cwithin carrier block B1.

Further, in the substrate processing apparatus of the present invention,a heating unit (PEB) may be mounted in interface portion B6, forexample, and in the case where the time between the light exposureprocessing and the succeeding heating processing in the heating unit(PEB) needs to be uniform, as in the case of using a chemicallyamplified resist solution for example, wafer W having undergone thelight exposure processing in light exposure device B7 may be transferredpreferentially to the heating unit (PEB) within a prescribed period oftime by delivery means 26. In this case, besides delivery means 26 ininterface portion B6, a sub-transfer arm 96 dedicated to transfer vialight exposure device B7→heating unit (PEB) may be provided, as shown,e.g., in FIGS. 15A and 15B.

In the example shown in FIGS. 15A and 15B, a shelf unit U7 provided witha peripheral light exposure device (WEE), a buffer cassette (BUF), atemperature regulating unit (CPL), and a heating unit (PEB) is arrangedbetween delivery means 26 and sub-transfer arm 96. Wafer W istransferred by delivery means 26 in the order of, e.g., delivery stage27→peripheral light exposure device (WEE)→buffer cassette(BUF)→temperature regulating unit (CPL). Thereafter, wafer W oftemperature regulating unit (CPL) is transferred by sub-transfer arm 96in the order of light exposure device B7→heating unit (PEB), and then,wafer W in heating unit (PEB) is transferred again by delivery means 26in the order of buffer cassette (BUF)→delivery stage 27. Further, it maybe configured such that the peripheral light exposure device is notprovided. In this case as well, wafer W is transferred in a similarmanner as described above, except that processing with the peripherallight exposure device is not conducted.

Further, the configuration of the substrate processing apparatus of thepresent invention is not limited to the one described above, as long asa series of processing are completed in each process block, and wafer Wwithin carrier block B1 is transferred via second transfer means 23 oftransfer block B2 to a process block to be subjected to predeterminedprocessing. Further, the numbers and types of the process units as wellas the layout thereof within the respective process blocks may bedifferent from each other, as long as the process blocks have the samesize in two dimensions. Furthermore, the same kind of processing or thedifferent kinds of processing may be carried out in the process blocks,as described above. Still further, the present invention is not onlyapplicable to the case of transferring first wafers of different lots,but also applicable to the case of transferring the succeeding wafers inthe same lot. In this case as well, unoccupied process block B3-B5 isdetermined and the wafer is transferred thereto. This can suppress thestate where transfer to process block B3-B5 is awaited, wherebythroughput can be improved.

More specifically, in the case where substrate carrier (C) stores firstand second lots of wafers W as a plurality of substrates, assume thatthe last wafer in the first lot is being processed in any of processblocks B3, B4, B5, and the remaining process block B3, B4, or B5 is notprocessing wafers. In such a case, means (83) for controlling the secondtransfer means controls the second transfer means (23) to transfer thefirst wafer W in the second lot to the relevant process block B3, B4 orB5 where processing is not being conducted, so that wafer W is processedin that process block B3, B4 or B5.

It may be configured not to include a light exposure device, or it maybe applied, e.g., to processing of forming an interlayer insulatingfilm, or to processing of forming a SOG (Spin On Glass) film on thesubstrate. In the present invention, the substrate is not limited to thesemiconductor wafer, but may be, e.g., a glass substrate for a liquidcrystal display, or a photo-mask substrate.

Further, it may be configured to include a plurality of light exposuredevices. FIG. 17 shows an example for sharing the light exposuredevices. Light exposure devices B7 include an ArF exposure machine and aKrF exposure machine, and a distance L between two light exposuredevices B7 is not less than 1000 mm. Both light exposure devices B7 areconnected to a coating and developing device via interface portion B6. Aspace permitting operation and maintenance is secured between lightexposure devices B7. The exposure machines are capable of simultaneousprocessing, and process blocks B3, B4, B5 having PRB of coating anddeveloping therefor are connected. When an EB (electron beam) exposuremachine is connected as light exposure device B7 for production ofvarious kinds of items with small quantities, parallel processing by thelight exposure machines can realize improvement of TP (throughput). Itis noted that in FIG. 17, the lots of wafers are introduced from aloading path 700 to carrier block B1 having a carrier station CS, andthen introduced to process blocks B3, B4, B5 via second transfer means23 incorporated in a docking station DS.

1. A substrate processing apparatus, comprising: a carrier blockincluding a carrier placement portion to/from which a substrate carrierstoring a plurality of substrates is loaded/unloaded, and first transfermeans for performing delivery of the substrate with respect to thesubstrate carrier placed on the carrier placement portion; secondtransfer means provided adjacent to the carrier block and fortransferring the substrate along a linear transfer path extending in alateral direction; a first delivery stage for performing delivery of thesubstrate between said first transfer means and said second transfermeans; a plurality of process blocks each including a plurality ofprocess units for performing predetermined processing on the substrate,third transfer means for transferring the substrate between theplurality of process units in each of the process blocks of theplurality of process blocks, and a second delivery stage for performingdelivery of the substrate between said second transfer means and saidthird transfer means, said plurality of process blocks being providedwith respect to a main body of the apparatus to be arranged along saidtransfer path, and performing a series of substrate processing on thesubstrates in units of the plurality of process blocks; a process blockcontrol portion controlling operations of said third transfer means andthe respective process units and outputting processing information ofthe substrates within the corresponding process block such thatpredetermined processing is performed on the substrates in each of theprocess blocks based on a predetermined recipe; and a controllerprogrammed to determine a process block where there is no substrate orwhere a final step for the last substrate within the relevant processblock will be finished earliest based on the processing information ofthe substrates from the process block control portions before thesubstrate is delivered from the first delivery stage to the secondtransfer means, and for controlling the second transfer means totransfer the substrate on said first delivery stage to the relevantprocess block; each of said plurality of process blocks including acoating unit for applying a resist solution to the substrate, adeveloping unit for performing developing processing on the substrateafter exposure to light, a heating unit for heating the substrate, thethird transfer means for transferring the substrate between the coating,developing, and heating units, and the second delivery stage forperforming delivery of the substrate between said second transfer meansand said third transfer means, and such application of the resistsolution and/or the developing processing after exposure to light beingperformed on the substrate in units of each process block.
 2. Thesubstrate processing apparatus according to claim 1, wherein first andsecond lots containing a plurality of substrates are stored in saidsubstrate carrier, and said means for controlling the second transfermeans controls the second transfer means such that, when the lastsubstrate in said first lot is being processed in one of said processblocks, if the other process block is not performing substrateprocessing, the first substrate in the second lot is transferred to thatprocess block portion which is not performing the processing to allowthe substrate to be processed in the relevant process block portion. 3.The substrate processing apparatus according to claim 1, wherein aninterface portion to which a light exposure device is connected isconnected to a side of said transfer path opposite to a side connectedto the carrier block.
 4. The substrate processing apparatus according toclaim 1, wherein an interface portion to which a light exposure deviceis connected is connected to a side of said transfer path opposite to aside connected to the process blocks.
 5. The substrate processingapparatus according to claim 1, wherein each process block of theplurality of process blocks includes a plurality of the coating units, aplurality of the developing units, and a plurality of the heating units,and said process block control portion further includes a function toselect the coating unit, the developing unit, and the heating unit foruse in the processing based on the process recipe of the substrate. 6.The substrate processing apparatus according to claim 1, wherein eachprocess block includes a liquid process unit performing processing onthe substrate using a chemical solution, a heating unit for heating thesubstrate, the third transfer means for transferring the substratebetween the units, and the second delivery stage for performing deliveryof the substrate between said second transfer means and said thirdtransfer means, and a series of processing are performed on thesubstrate in units of each process block.
 7. The substrate processingapparatus according to claim 6, wherein each process block of theplurality of process blocks includes a plurality of the liquid processunits and a plurality of the heating units, and said process blockcontrol portion further includes a function to select the liquid processunit and the heating unit for use in the processing based on the processrecipe of the substrate.
 8. The substrate processing apparatus accordingto claim 6, wherein said liquid process unit is for forming a coatingfilm.
 9. The substrate processing apparatus according to claim 6,wherein said liquid process unit is for coating the substrate with achemical solution containing a precursor of an insulating film.
 10. Thesubstrate processing apparatus according to claim 1, wherein saidplurality of process blocks are formed to have the same size in twodimensions.
 11. The substrate processing apparatus according to claim 1,wherein said second transfer means is provided at a transfer block thatextends along an arrangement of the plurality of process blocks, andeach process block is configured to be attachable to and detachable fromthe transfer block.